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Kelly KBL Brushless Motor Controller User

’s Manual

V 3.4

12

3.2.2 Wiring of BLDC Motor Controller

Figure 6: Standard Wiring for Controllers Rated Equal or Lower Than 120V.

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Summary of Contents for KBL24101X

Page 1: ...oller User s Manual Devices Supported KBL24101X KBL48151X KBL72501E KBL24151X KBL48221X KBL96151 KBL24221X KBL48301X KBL96201 KBL24301X KBL48401E KBL96251 KBL24401X KBL48501E KBL36101X KBL72101X KBL36151X KBL72151X KBL36221X KBL72221X KBL36301X KBL72301X KBL48101X KBL72401E Rev 3 4 July 2022 ...

Page 2: ...unctions 3 2 2 Features 4 2 3 Specifications 5 2 4 Naming Regulations 5 Chapter 3 Wiring and Installation 7 3 1 Mounting the Controller 7 3 2 Connections 9 3 3 Installation Check List 14 Chapter 4 Maintenance 15 4 1 Cleaning 15 4 2 Configuration 15 Table 1 LED CODES 16 Green LED Codes 16 Red LED Codes 16 Table 2 KBL Controller CAN Commands List 18 Contact Us 22 ...

Page 3: ... Controls LLC Kelly s programmable motor controllers provide efficient smooth and quiet controls for golf carts go carts electric motorcycles forklifts hybrid vehicles electric vehicles and electric boats as well as industrial motor speed or torque control It uses high power MOSFET s and PWM to achieve efficiencies of up to 99 in most cases A powerful microprocessor brings in comprehensive and pre...

Page 4: ... various kinds of sensors including Hall effect type 10 3 switch inputs which are activated by connection to Ground Default to throttle switch brake switch and reversing switch Closing to ground is to activate 11 3 analog 0 5V inputs that default to throttle input brake input and motor temperature input 12 Pulsed reverse alarm output 13 Main contactor driver Cutting off the power if any fault is d...

Page 5: ... 6 Current sense on all 3 motor phases 7 Current control loop 8 Hardware over current protection 9 Hardware over voltage protection 10 Support torque mode speed mode and balanced mode operation 11 Configurable limit for motor current and battery current 12 Low EMC 13 LED fault code 14 Battery protection current cutback warning and shutdown at configurable high and low battery voltage 15 Rugged alu...

Page 6: ...le battery voltage range B Standard Throttle Input 0 5 Volts 3 wire resistive pot 1 4 Volts hall active throttle Analog Brake and Throttle Input 0 5 Volts Producing 0 5V signal with 3 wire pot Reverse Alarm Main Contactor Coil Driver Meter Full Power Operating Temperature Range 0 ﹾ Ｃ to 50 ﹾ Ｃ controller case temperature Operating Temperature Range 30 ﹾ Ｃ to 90 ﹾ Ｃ 100 ﹾ Ｃ shutdown controller case...

Page 7: ...2 24 30 KBL36101X 150 100 60 24 36 45 KBL36151X 200 150 80 24 36 30 KBL36221X 280 220 112 24 36 30 KBL36301X 350 300 140 24 36 30 KBL48101X 150 100 60 24 48 60 KBL48151X 200 150 80 24 48 60 KBL48221X 280 220 112 24 48 60 KBL48301X 350 300 140 24 48 60 KBL48401E 450 400 160 24 48 60 KBL48501E 550 500 200 24 48 60 KBL72101X 150 100 60 24 72 86 KBL72151X 220 150 88 24 72 86 KBL72221X 280 220 112 24 7...

Page 8: ...o ensure full rated output power the controller should be fastened to a clean flat metal surface with four or six screws Applying silicon grease or some other thermal conductive material to contact surface will enhance thermal performance Proper heat sinking and airflow are vital to achieve the full power capability of the controller The case outline and mounting holes dimensions are shown in Figu...

Page 9: ...Kelly KBL Brushless Motor Controller User s Manual V 3 4 8 Height 84 millimeters Figure 2 KBL E mounting holes dimensions dimensions in millimeters ...

Page 10: ...two plugs J1 J2 are provided for connecting to the battery motor and control signals in the front of the controller shown as Figure 3 4 and 5 Figure 3 Front panel of KBL KBL X motor controller Figure 4 Front panel of KBL E motor controller B battery positive B battery negative A Output U 1 A phase B Output V 2 B phase C Output W 3 C phase ...

Page 11: ... receiver 9 RS232 transmitter 10 CAN bus high 11 CAN bus low 12 Reserved 13 RTN Signal return or power supply return 14 Red LED Fault code J2 Pin Definition 1 PWR Controller power supply input 2 RTN Signal return or power supply return 3 RTN Signal return 4 12V high level brake and motor temperature input 5 Throttle analog input 0 5V 6 Brake analog input 0 5V 7 5V 5V supply output 40mA 8 Micro_SW ...

Page 12: ...4 Switch to ground is active Open switch is inactive Caution Do not apply power until you are certain the controller wiring is correct and has been double checked Wiring faults will damage the controller Ensure that the B wiring is securely and properly connected before applying power The preferred connection of the system contactor or circuit breaker is in series with the B line All contactors or...

Page 13: ...Kelly KBL Brushless Motor Controller User s Manual V 3 4 12 3 2 2 Wiring of BLDC Motor Controller Figure 6 Standard Wiring for Controllers Rated Equal or Lower Than 120V ...

Page 14: ...Kelly KBL Brushless Motor Controller User s Manual V 3 4 13 Figure 7 BLDC controller preferred wiring 24V supply is preferred ...

Page 15: ...re the PWR switch and the brake is off Use well insulated tools Make sure the wire is connected correctly Turn the PWR switch on The Green LED stay on steadily and Red LED turns off when the controller operates normally If this does not happen check continuity of the PWR and return The fault code will be detected automatically at restart With the brake switch open select a direction and operate th...

Page 16: ...oist rag Make sure that the controller is dry before reconnecting the battery Make sure the connections to the bus bars if fitted are tight To avoid physically stressing the bus bars use two well insulated wrenches 4 2 Configuration You can configure the controller with a host computer through either an RS232 or USB port Disconnect motor wiring from controller Do not connect B throttle and so on T...

Page 17: ...LED Code Explanation Solution 1 2 Over voltage error 1 Battery voltage is too high for the controller Check battery volts and configuration 2 Regeneration over voltage Controller will have cut back or stopped regen 3 This only accurate to 2 upon Overvoltage setting 1 3 Low voltage error 1 The controller will clear after 5 seconds if battery volts returns to normal 2 Check battery volts recharge if...

Page 18: ... a direction change unless the throttle or speed is at zero Fault clears when throttle is released 4 1 Regen or Start up over voltage Motor drive is disabled if an over voltage is detected at start up or during regen The voltage threshold detection level is set during configuration 4 2 Hall sensor error 1 Incorrect or loose wiring or a damaged hall sensor 2 Also be caused by incorrect hall angle c...

Page 19: ... response Length 8 data 0 data 7 Controller s model in ASCII format 8 bytes Description Getting controller s model no E g 0x4B 0x42 0x4C is K B L 0x30 is 0 INFO_MODULE_NAME constant is defined as 64 Command CCP_FLASH_READ Length 3 data 0 0xF2 data 1 INFO_SOFTWARE_VER data 2 2 Controller response Length 2 data 0 data 1 software version in BCD alike format two bytes Description Getting controller s ...

Page 20: ...H_READ Length 3 data 0 0xF2 data 1 CAL_BRAKE_DEAD_ZONE_HIGH data 2 1 Controller response Length 1 data 0 Brake_Dead_Zone_High Desccription Getting controller s Brake high end dead zone CAL_BRAKE_DEAD_ZONE_HIGH constant is defined as 39 The maximum value of Brake is 100 If the value of Brake High end Dead Zone is 80 indicating 80 high end dead zone 80 100 is 80 Command CCP_A2D_BATCH_READ1 Length 1 ...

Page 21: ...abling motor rotation or disabling 1 enable 0 disable 3 data 2 is defined as the temperature of motor in Celsius temperature If the temperature sensor is not connected the controller returns 0xFF 4 data 3 data 5 are defined as controller inside temperature in Celsius temperature The value of data 4 and data 5 are inaccurate below 30 Command CCP_MONITOR2 Length 1 data 0 0x37 Controller response Len...

Page 22: ...DING constant is defined as 0 Command COM_SW_REV Length 2 data 0 0x44 data 0 COM_READING Controller response Length 1 data 0 Current Reverse switch status Description Getting Reverse swith status 1 active 0 inactive COM_READING constant is defined as 0 NOTICE 1 CAN bus rate should be configured to 1Mbit s 2 If the command is out of above commands Controller response Length 1 data 0 CCP_INVALID_COM...

Page 23: ...Kelly KBL Brushless Motor Controller User s Manual V 3 4 22 Contact Us Kelly Controls LLC Home Page http www KellyController com E mail Support KellyController com Phone 01 224 637 5092 ...

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